Waterproofing and moisture control insulation

ABSTRACT

Described is moisture-controlling insulation apparatus that allows water and moisture to move from the space between an interior and exterior wall of a building to a drainage system. The water moves along a series of interconnecting channels in the apparatus. The channels are configured such that water will not settle in the channels before reaching the drainage system.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application Ser. No. 62/652,892 filed Apr. 4, 2018, the disclosure of which is incorporated by reference herein.

BACKGROUND

If water or moisture seeps past the exterior-wall barriers of a building, the moisture may become trapped inside the walls of a building. The trapped moisture may damage the interior structure of the building. For instance, moisture that has infiltrated past the exterior-wall barrier of a building may cause mold to grow inside the walls, and rot to occur over time. Damage caused by exposure to water including that from mold and rot is extremely costly to repair.

One method to prevent water from breaching the exterior-wall barriers of a building is to seal the outer-most exterior surface of a building. This is commonly referred to as a “barrier system.” Unfortunately, barrier systems alone are not foolproof, and any imperfection in the seal will likely allow water to seep into the interior portions of a building. Further, over time, exterior seals degrade, and permit moisture to enter into the interior portion of a building.

Another method to prevent moisture from entering into a building is to create a drainage system. The drainage system usually includes a cladding material, which forms the exterior surface of the building and is generally resistive to water. The draining system also includes a water barrier that is installed against the interior wall portion of a building. Sandwiched between the cladding and the water barrier is a drainage space, i.e. a cavity, in which water can flow and drain out from behind the cladding and against the water-resistive barrier.

These water barrier/drainage systems are often susceptible to leakage, and trapped water. They are also made of expensive materials and are costly to install.

SUMMARY

Described is a moisture-controlling insulation apparatus that allows water that has collected between the interior and exterior walls of a building to move to a drainage system.

The apparatus includes foam insulation boards that are placed between the interior and exterior walls of a building. Each board includes a series of channels carved into one surface, i.e., the front surface, of the board. The front surface of each board can be secured to either the interior or exterior wall. The opposing surface, i.e., the rear surface, of each board is flat and can also be secured to either the interior or exterior wall. Each board can vary in size, but when all of the boards have been installed, they may cover the entirety of the outer wall area of a building.

The channels on the front surface of each board are configured such that they create a diamond-shaped lattice on each board. They are also configured such that they align with the channels of another board when the edges of two boards are placed against each other. This configuration allows water to flow toward to the bottom of the boards without settling before reaching the bottom of all of the boards. At the bottom of all of the boards, a homeowner can install a drainage system to allow water to flow away from the building. In another embodiment, each board includes a channel along each edge of the board. These additional channels allow water to flow from one board to another even if the channels along the face of each board are not perfectly aligned.

The channels on the front surface of each board can have a square-shaped cross-section with about a one-inch length on each side of the square. The size and shape of the cross section of the channels can vary. However, the boards provide insulation for the building, so the cross-section of the channels needs to be sufficiently small as to minimize the amount of insulating material removed from each board. The channels also need to be sufficiently large as to allow water to flow unimpeded down the channels. Given the benefit of this disclosure, one skilled in the art can determine the appropriate size and shape of the cross-section of the channels.

Each board is made of extruded polystyrene. Extruded polystyrene has two properties that make it a suitable material for this apparatus. Extruded polystyrene acts as a good insulator and is also highly repellant to moisture. Some other common insulation materials, such as expanded polystyrene, tend to absorb moisture instead of repel it. Over time, this can lead to a build-up of moisture in the insulation boards between the inner and outer walls of the building. The moisture repellant property of extruded polystyrene prevents moisture from being trapped in the insulation boards and allows water to flow unimpeded to the drainage system.

To increase the insulation of the building, the boards can be stacked in layers where either the front or rear surface of one board is secured to either the front or rear surface of another board. This also increases the number of channels through which water flows to the drainage system.

The boards can be shaped to fit around fixtures in the walls such as windows. They can also be shaped to allow water to flow around protrusions in the building or foundation.

After the apparatus is installed around the walls of a basement, it diverts water that would otherwise flow into the basement to a drainage system. This reduces the amount of water that collects in the basement thereby alleviating another common issue for homeowners. By reducing the amount of moisture in a basement, the apparatus also allows a homeowner to use their basement more comfortably.

In addition, the boards allow a wall to dry outwardly if the wall has a water resistive barrier. Even though vapor does not penetrate through the boards, the channels give vapor avenues to travel through, which facilitates drying of the wall.

Over time, the apparatus can save a homeowner money by reducing the likelihood that the homeowner will need to repair walls damaged by moisture or mold.

The foregoing outlines examples of this disclosure so that those skilled in the relevant art may better understand the detailed description that follows. Additional embodiments and details will be described hereinafter. Those skilled in the relevant art should appreciate that they can readily use any of these disclosed embodiments as a basis for designing or modifying other structures or functions for carrying out the invention, without departing from the spirit and scope of the invention.

Reference herein to “one embodiment,” “an embodiment,” “an aspect,” “an implementation,” “an example,” or similar formulations, means that a particular feature, structure, operation, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, different appearances of such phrases or formulations herein do not necessarily refer to the same embodiment. Furthermore, various particular features, structures, operations, or characteristics may be combined in any suitable manner in one or more embodiments.

BRIEF DESCRIPTION OF THE DRAWINGS

The detailed description is described with reference to the accompanying figures. In the figures, the left-most digit(s) of a reference number identifies the figure in which the reference number first appears. The figures are not necessarily drawn to scale.

FIG. 1 shows a cross section of an outer wall and basement wall of a building including an embodiment of the apparatus and drainage system.

FIG. 2 shows an isometric view of a section of the apparatus.

FIG. 3 shows multiple layers of insulation boards under a window frame in an embodiment of the apparatus.

DETAILED DESCRIPTION

Described is a moisture-controlling insulation apparatus that allows water that has collected between the interior and exterior walls of a building to move to a drainage system. For instance, FIG. 1 shows an embodiment of the apparatus 100 installed between the interior wall 102 and the exterior wall 104 of a building.

In FIG. 1, apparatus 100 is shown as including a series of foam insulation boards (collectively, 106). FIG. 1 also shows a drainage system 108 including gravel 110 and several pipes 112(A), 112(B), 112(C) (collectively, 112), the pipes 112 being located near the foundation of the building 114. Apparatus 100 allows moisture that has collected between interior wall 102 and the exterior wall 104 to flow through the series of foam insulation boards 106 to a section at the bottom of the series of boards 116 and into drainage system 108. The movement of moisture is accomplished in part as a result of the design of the foam insulation boards 106, discussed below.

Over time, apparatus 100 can save a homeowner money by reducing the likelihood that a homeowner will need to repair walls damaged by moisture or mold.

Foam Insulation Board

FIG. 2 shows an isometric view of a section of apparatus 100 revealing foam insulation board 200(A) and foam insulation board 200(B) (each also referred to as board 200, because each board is similarly configured). Board 200 is included in the series of foam insulation boards 106. Board 200 includes a series of channels (collectively, 202) carved into one surface, the front surface 204, of board 200. Front surface 204 of board 200 can be secured to either interior wall 102 or exterior wall 104. The opposing surface, the rear surface 206 (not visible for board 200(A), but visible for board 200(B)), of board 200 can also be secured to either interior wall 102 or exterior wall 104. As shown in FIG. 2, rear surface 206 is primarily flat with no indentations or extrusions. Board 200 can vary in size, but when all of the boards have been installed as a series of foam insulation boards 106, they cover nearly the entirety of the outer wall area of the building.

Channels 202 on front surface 204 of board 200 are configured such that they create a diamond-shaped lattice pattern on front surface 204. Channels 202 are also configured such that they align with the channels of another board when the edges of two boards are placed against each other. This configuration allows water to flow toward to the bottom 116 of the series of foam insulation boards 106 without settling before reaching the bottom 116 of the series of foam insulation boards 106. Drainage system 108 at the bottom 116 of the series of foam insulation boards 106 allows water to flow away from the building. In another embodiment that is not pictured, board 200 includes a channel along each edge of board 200. These additional channels allow water to flow from one board to another even if channels 202 are not perfectly aligned between boards.

Channels 202 on front surface 204 of board 200 have a square-shaped cross-section with about a one-inch length on each side of the square-shaped cross-section. In another embodiment of apparatus 100, the size and shape of the cross-section of the channels can vary. (Not shown). However, the series of foam insulation boards 106 provide insulation for the building, so the cross-section of channels 202 needs to be sufficiently small as to minimize the amount of insulating material removed from each board. Channels 202 also need to be sufficiently large as to allow water to flow unimpeded down channels 202. Given the benefit of this disclosure, one skilled in the art can determine the appropriate size and shape of the cross-section of channels 202.

Board 200 is made of extruded polystyrene. Extruded polystyrene has two properties making it a suitable material for apparatus 100. First, extruded polystyrene acts as a good insulator and, second, extruded polystyrene is highly repellent to moisture. Many other common insulation materials, such as expanded polystyrene, tend to absorb moisture instead of repelling it. The moisture repellent property of extruded polystyrene prevents moisture from being trapped in the boards and allows water to flow unimpeded to drainage system 108.

Insulation Board Configuration

As shown in FIG. 3, stacking board 200(A) and board 200(B) in layers can increase the insulation of a building where either the front or rear surface of board 200(A) is secured to either the front or rear surface of board 200(B). This also increases the number of channels 202 through which water flows to the drainage system.

Also shown in FIG. 3, boards 106 can be shaped to fit under or around fixtures in the wall 102 and wall 104 such as a window 300. Other fixtures can include but are not limited to doors, utility pipes, or electrical cables. (Not shown.)

Returning to FIG. 1, boards 106 can also be shaped to allow water to flow around protrusions 118 in wall 102 or foundation 114. In the displayed embodiment, boards 106 are configured around a section of wall 102 designed to support wall 104. Below ground, boards 106 are reinforced by gravel 110. Gravel 110 provides additional avenues for water to flow to pipes 112.

In the displayed embodiment, apparatus 100 is installed around interior wall 102 and diverts water into drainage system 108. If interior wall 102 acts as the walls of a basement, then a lesser amount of water collects in the basement, thereby alleviating another common issue for homeowners. By reducing the amount of water and moisture in a basement, apparatus 100 also allows a homeowner to use their basement more comfortably.

In addition to facilitating the movement of water, apparatus 100 facilitates the movement of vapor. Even though vapor does not penetrate through boards 106, channels 202 give vapor avenues to travel through. Even if front wall 104 includes a water resistive barrier (not shown), front wall 104 can still dry outwardly, because vapor travels though channels 106.

Drainage System

Continuing with FIG. 1, apparatus 100 is shown as including drainage system 108. Drainage system 108 moves water that has flowed through series of foam boards 106 away from the building. Drainage system includes pipes 112 for water to flow into and be transported elsewhere. Given the benefit of this disclosure, those skilled in the art would recognize that pipes 112 can move water to various destinations including but not limited to a groundwater system or a municipal sewage system. In another embodiment, drainage system 108 includes a pumping system to move water through pipes 112. (Not shown.)

Drainage system also includes gravel 110. Gravel 110 provides additional avenues for water to flow through in order to reach pipes 112. Providing additional avenues for water to flow through reduces the likelihood that water builds up in channels 202, which also reduces any possible water damage to inner wall 102 and outer wall 104.

Although the subject matter has been described in language specific to structural features and/or methodological acts, it is to be understood that the subject matter defined in the appended claims is not necessarily limited to the specific features or acts described. Rather, the specific features and acts are disclosed as illustrative forms of implementing the claims. 

1.
 1. A moisture-controlling insulation apparatus for a building comprising: a series of rectangular foam boards and a drainage system; wherein the rectangular foam boards are primarily composed of extruded polystyrene and include two oppositely facing surfaces, a front surface and a rear surface, each surface being configured to abut a wall surface, and four edges that form four sides of the rectangular shape of each board; wherein the front surface of the rectangular foam boards include a series of channels where each channel is configured to begin at an edge of each foam board and end at a different edge of each foam board such that each channel begins at a point where a channel on another board begins, allowing water to flow from one foam board to another.
 2. The apparatus of claim 1, wherein the series of channels is configured to form a diamond-shaped lattice on the front surface of the foam boards.
 3. The apparatus of claim 1, wherein the channels have a square-shaped cross-section such that each side of the square-shaped cross-section has a length of about one inch.
 4. The apparatus of claim 1, wherein the foam boards further include a channel along each of the four edges of each foam board.
 5. The apparatus of claim 1, further including a second series of rectangular foam boards; wherein the second series of rectangular foam boards are primarily composed of extruded polystyrene and include two oppositely facing surfaces, a front surface and a rear surface, each surface being configured to abut a wall surface, and four edges that form four sides of the rectangular shape of each board; wherein the front surface of the second series of rectangular foam boards include a series of channels where each channel is configured to begin at an edge of each foam board and end at a different edge of each foam board such that each channel begins at a point where a channel on another board begins, allowing water to flow from the one foam board to another; and wherein the front surface of each of the foam boards of the second series of rectangular foam boards is secured to the rear surface of the foam boards of claim
 1. 6. The apparatus of claim 1, further including a second series of rectangular foam boards wherein the second series of rectangular foam boards are primarily composed of extruded polystyrene and include two oppositely facing surfaces, a front surface and a rear surface, each surface being configured to abut a wall surface, and four edges that form four sides of the rectangular shape of each board; wherein the front surface of the second series of rectangular foam boards include a series of channels where each channel is configured to begin at an edge of each foam board and end at a different edge of each foam board such that each channel begins at a point where a channel on another board begins, allowing water to flow from the one foam board to another; and wherein the rear surface of each of the foam boards of the second series of rectangular foam boards is secured to the rear surface of the foam boards of claim
 1. 7. The apparatus of claim 1, further including a drainage system, wherein the drainage system includes at least one pipe located underground, proximal to a building's foundation and also proximal to the series of foam insulation boards, where each pipe is configured such that water flows from the series of foam insulation boards into each pipe and then away from a building.
 8. The apparatus of claim 1, further including a drainage system, wherein the drainage system includes gravel located underground, proximal to a building's foundation and also proximal to the series of foam insulation boards, where the gravel is configured such that water flows from the series of foam insulation boards into the gravel and then away from a building.
 9. The apparatus of claim 1, further including a drainage system, wherein the drainage system includes a pumping system configured to pump water that has flowed through the series of foam insulation boards from a building.
 10. A moisture-controlling insulation apparatus for a building comprising: at least one rectangular foam board primarily composed of extruded polystyrene that includes two oppositely facing surfaces, a front surface and a rear surface, each surface being configured to abut a wall surface, and four edges that form the sides of the rectangular shape of the board; wherein the front surface of the rectangular foam board includes a series of channels where each channel is configured to begin at an edge of the rectangular foam board and end at a different edge of the rectangular foam board.
 11. The apparatus of claim 10, wherein the series of channels is configured to form a diamond-shaped lattice on the front surface of the rectangular foam board.
 12. The apparatus of claim 10, wherein each channel has a square-shaped cross-section such that each side of the square-shaped cross-section has a length of about one inch.
 13. The apparatus of claim 10, wherein the rectangular foam board further include a channel along each of the four edges of the rectangular foam board.
 14. The apparatus of claim 10, further including at least a second rectangular foam board; wherein the second rectangular foam board is primarily composed of extruded polystyrene and include two oppositely facing surfaces, a front surface and a rear surface, each surface being configured to abut a wall surface, and four edges that form four sides of the rectangular shape of each board; wherein the front surface of the second rectangular foam board includes a series of channels where each channel is configured to begin at an edge of the rectangular foam board and end at a different edge of the second rectangular foam board; and wherein the front surface of the second rectangular foam board is secured to the rear surface of the rectangular foam board of claim
 10. 15. The apparatus of claim 10, further including at least a second rectangular foam board; wherein the second rectangular foam board is primarily composed of extruded polystyrene and include two oppositely facing surfaces, a front surface and a rear surface, each surface being configured to abut a wall surface, and four edges that form four sides of the rectangular shape of each board; wherein the front surface of the second rectangular foam board includes a series of channels where each channel is configured to begin at an edge of the rectangular foam board and end at a different edge of the second rectangular foam board; and wherein the rear surface of the second rectangular foam board is secured to the rear surface of the rectangular foam board of claim
 10. 16. (canceled) 